IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0592856
(2006-11-03)
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등록번호 |
US-7699686
(2010-05-20)
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발명자
/ 주소 |
- Hahn, Henry N.
- Dutton, Ronald J.
- Crawford, Larry F.
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출원인 / 주소 |
- Severstal Sparrows Point, LLC
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대리인 / 주소 |
Masteller, Jr., Harold I.
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인용정보 |
피인용 횟수 :
1 인용 특허 :
10 |
초록
The present invention is directed to a method of polishing a minimum spangle aluminum-zinc alloy hot-dip coating applied to sheet steel to provide a polished hot-dip coating having a continuous, consistent surface appearance suitable for use in an unpainted condition.
대표청구항
▼
We claim: 1. A method for polishing a hot-dip aluminum zinc alloy coated sheet steel article to produce a polished coated surface having a continuous and consistent stainless steel like appearance, the steps of the method comprising: a) providing a sheet steel substrate with a hot-dip aluminum zinc
We claim: 1. A method for polishing a hot-dip aluminum zinc alloy coated sheet steel article to produce a polished coated surface having a continuous and consistent stainless steel like appearance, the steps of the method comprising: a) providing a sheet steel substrate with a hot-dip aluminum zinc alloy coating applied thereto, the hot-dip aluminum zinc alloy coating having a spangle facet size less than about 500 microns; b) embossing said hot-dip aluminum zinc alloy coating with at least one textured roll, said at least one textured roll applying an effective roll force that embosses said hot-dip aluminum zinc alloy coating without embossing the sheet steel substrate; and c) polishing said embossed hot-dip aluminum zinc alloy coating, the polished embossed coating having said continuous and consistent stainless steel like appearance. 2. The method recited in claim 1, wherein said at least one textured roll has a textured workface, and the method further includes: imprinting a mirror image of said textured workface into the hot-dip alloy coating without imprinting the sheet steel substrate. 3. The method recited in claim 1, wherein said applied effective roll force is less than about 22,000 newtons/cm. 4. The method recited in claim 1, wherein said applied effective roll force is between about 10,500 and about 22,000 newtons/cm. 5. The method recited in claim 2, wherein said textured workface has a T-Ra between about 2 microns and about 5 microns. 6. The method recited in claim 2, wherein said textured workface has a T-Ra between about 2.3 microns and about 2.8 microns. 7. The method recited in claim 2, wherein said mirror image has a L-Wca between about 0.50 microns and 0.70 microns, and a T-Wca between about 0.76 microns and about 1.10 microns. 8. The method recited in claim 2, wherein said mirror image has a L-Wca of about 0.64 microns and a T-Wca of about 0.94 microns. 9. The method recited in claim 2, wherein said mirror image has a L-Ra between about 0.56 microns and about 0.71 microns and a T-Ra between about 1.00 microns and about 1.30 microns. 10. The method recited in claim 2, wherein said mirror image has a L-Ra of about 0.64 microns and a T-Ra of about 1.14 microns. 11. The method recited in claim 2, wherein said mirror image has a L-PC between about 32 peaks per/cm and about 72 peaks per/cm and a T-PC between about 85 and about 97 peaks/cm. 12. The method recited in claim 2, wherein said mirror image has a L-PC of about 49 peaks/cm and a T-PC of about 90 peaks/cm. 13. The method recited in claim 1, wherein the hot-dip aluminum zinc alloy coated sheet steel article has an as-coated thickness between about 0.73 mils and 0.83 mils and said embossed hot-dip aluminum zinc alloy coating has a thickness between about 0.73 mils and 0.83 mils. 14. The method recited in claim 1, wherein said polishing step further comprises: polishing said embossed hot-dip aluminum zinc alloy coating with at least two rotating abrasive belts, said abrasive belts rotating at a belt speed greater than 1500 SFPM, said abrasive belts rotating at different respective belt speeds. 15. The method recited in claim 14, wherein said abrasive belts rotate at a different respective belt speeds between about 1500 SFPM and about 4000 SFPM. 16. The method recited in claim 14, wherein said abrasive belts rotate at a different respective belt speeds between about 1800 SFPM and about 3400 SFPM. 17. The method recited in claim 14, wherein said at least two abrasive belts comprise a polishing surface of 120 grit or finer. 18. The method recited in claim 14, wherein said abrasive belts comprise between about 320 grit and about 120 grit polishing material. 19. The method recited in claim 14, wherein said abrasive belts comprise a 180 grit polishing material. 20. The method recited in claim 14, wherein said polishing step further comprises: flushing said embossed hot-dip aluminum zinc alloy coating surface with a lubricant. 21. The method recited in claim 20, wherein said lubricant is water based. 22. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-Wca between about 0.67 microns and about 1.43 microns and a T-Wca between about 0.40 microns and about 0.50 microns. 23. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-Wca between about 0.70 microns and about 0.80 microns and a T-Wca between about 0.40 microns and about 0.46 microns. 24. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-Wca of about 0.75 microns and a T-Wca of about 0.44 microns. 25. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-Ra between about 0.60 microns and to about 1.00 microns and a T-Ra between about 1.40 microns and about 1.80 microns. 26. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-R hd a between about 0.70 microns and about 0.90 microns and a T-Ra between about 1.50 microns and about 1.70 microns. 27. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-Ra of about 0.76 microns and a T-Ra of about 1.58 microns. 28. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-PC between about between about 20 peaks/cm and about 37 peaks/cm and a T-PC between about 177 peaks/cm and about 221 peaks/cm. 29. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-PC between about 24 peaks/cm and about 32 peaks/cm and a T-PC between about 189 peaks/cm and about 209 peaks/cm. 30. The method recited in claim 1, wherein said polished embossed hot-dip aluminum zinc alloy coating has a L-PC of about 25.8 peaks/cm and a T-PC of about 204 peaks/cm. 31. The method recited in claim 1, wherein said hot-dip aluminum zinc alloy coating comprises: a minimum spangle hot-dip aluminum-zinc alloy coating containing between about 25% and 70% aluminum by weight. 32. The method recited in claim 1, wherein said hot-dip aluminum zinc alloy coating comprises: a minimum spangle aluminum-zinc alloy hot-dip coating containing about 55% aluminum by weight. 33. The method recited in claim 1, wherein said minimized spangle aluminum zinc hot-dip coating has a facet size between about 200 microns and about 500 microns. 34. The method recited in claim 1, wherein said minimized spangle aluminum zinc hot-dip coating having a facet size is less than about 300 microns. 35. The method recited in claim 1, wherein said hot-dip aluminum-zinc alloy coating is spangle free. 36. A method for producing an embossed sheet steel article that simulates a stainless steel surface when polished from a sheet steel substrate having an aluminum-zinc alloy hot-dip coating applied thereto, said aluminum-zinc alloy hot-dip coating having a minimized spangle facet size less than about 500 microns, the steps of the method comprising: passing the aluminum-zinc alloy hot-dip coated sheet steel substrate between work rolls, at least one work roll having a textured workface; and applying an effective roll force that embosses a mirror image of said textured workface into said aluminum-zinc alloy hot-dip coating without embossing said sheet steel substrate, said mirror image having surface characteristics that produce said continuous consistent stainless steel like appearance when said embossed aluminum-zinc alloy hot-dip coating is polished. 37. The method recited in claim 36, wherein said applied effective roll force is between about 10,500 and about 22,000 newtons/cm. 38. The method recited in claim 36, wherein said textured workface has a T-Ra between about 2 microns and about 5 microns. 39. The method recited in claim 36, wherein said textured workface has a T-Ra between about 2.3 microns and about 2.8 microns. 40. The method recited in claim 36, wherein said imprinted mirror image has a L-Wca between about 0.50 microns and 0.70 microns, and a T-Wca between about 0.76 microns and about 1.10 microns. 41. The method recited in claim 36, wherein said imprinted mirror image has a L-Wca of about 0.64 microns and a T-Wca of about 0.94 microns. 42. The method recited in claim 36, wherein said imprinted mirror image has a L-Ra between about 0.56 microns and about 0.71 microns and a T-Ra between about 1.00 microns and about 1.30 microns. 43. The method recited in claim 36, wherein said imprinted mirror image has a L-Ra of about 0.64 microns and a T-Ra of about 1.14 microns. 44. The method recited in claim 36, wherein said imprinted mirror image has a L-PC between about 32 peaks per/cm and about 72 peaks per/cm and a T-PC between about 85 and about 97 peaks/cm. 45. The method recited in claim 36, wherein said imprinted mirror image has a L-PC of about 49 peaks/cm and a T-PC of about 90 peaks/cm. 46. The method recited in claim 36, wherein the coated sheet steel article has an as-coated thickness between about 0.73 mils and 0.83 mils and said embossed coated sheet steel article has a coating thickness between about 0.73 mils and 0.83 mils. 47. The method recited in claim 36, wherein said embossed hot-dip coating has a thickness between about 0.73 mils and 0.83 mils. 48. The method recited in claim 36, wherein said aluminum-zinc alloy hot-dip coating contains between about 25% and about 70% aluminum by weight. 49. The method recited in claim 36, wherein said aluminum-zinc alloy hot-dip coating contains about 55% aluminum by weight. 50. The method recited in claim 36, wherein said aluminum-zinc alloy hot-dip coating has a spangle facet size between about 200 microns and about 500 microns. 51. The method recited in claim 36, wherein said aluminum-zinc alloy hot-dip coating has a spangle facet size less than about 300 microns. 52. The method recited in claim 36, wherein said aluminum-zinc alloy hot-dip alloy coating is spangle free. 53. A method for simulating a stainless steel appearance along the surface of a hot-dip coated sheet steel article, the steps of the method comprising: providing a zinc alloy hot-dip coated sheet steel substrate, the zinc alloy hot-dip coating having a spangle facet size less than about 500 microns; embossing at least one surface of said zinc alloy hot-dip coating without embossing said sheet steel substrate; and polishing said at least one embossed zinc alloy hot-dip coated surface with at least two rotating abrasive belts, said polished surface providing said simulated stainless steel surface.
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